Air conduit and diffuser assembly

ABSTRACT

An air conduit and diffuser assembly for use in a room below the room ceiling in full view includes a conduit with a central cavity to conduct air into the room and openings through the conduit to diffuse the air throughout the room, the conduit being attached by rods extending between the ceiling and the upper portion of the conduit. The preferred embodiment includes a cavity in the upper portion for mounting a light fixture or the like, a utility channel in the central cavity to carry utilities into the room, and both metering and diffuser opening in the upper half of the conduit to direct the flow of air downwardly along the outside of the conduit. An alternative exemplary embodiment has a universal upper portion with the diffuser openings therein which accepts various sizes of lower portions for different central cavity sizes.

United States Patent Lambert Aug. 19, 1975 AIR CONDUIT AND DIFFUSER ASSEMBLY Primary Examiner-William E. Wayner [75] Inventor: Robert R. Lambert, Glendora, Calif, [73] Assignee: Wehr Corporation, Milwaukee, Wis. [57] ABSTRACT Filed, Mar 25 1974 An air conduit and diffuser assembly for use in a room below the room ceiling in full view includes a conduit [21] Appl. No.: 454,099 with a central cavity to conduct air into the room and openings through the conduit to diffuse the air Related Apphcanon Data throughout the room, the conduit being attached by [62] Division of Ser. No. 2,112, Jan. 12, 1970, Pat. No. rods extending between the ceiling and the upper tion of the conduit. The preferred embodiment includes a cavity in the upper portion for mounting a 2? 'i 29/455 light fixture or the like, a utility channel in the central nt. cavity to carry utilities into the room, and both meter [58] Field of Search 98/40 D, 40 C, 40 DL; in and diffuser o enin in the u er half of the Com 248/59- 29/464 455- 138/107- 240/47 p g pp duit to direct the flow of air downwardly along the outside of the conduit. An alternative exemplary em- [56] References cued bodiment has a universal upper portion with the dif- UNITED STATES PATENTS fuser openings therein which accepts various sizes of 3,106,146 10/1963 La Vigne 98/40 D X lower portions for different central cavity sizes. 3,202,077 8/1965 Lee 98/40 D 5 Claims, 6 Drawing Figures PATENTED AUG 1 9 I975 STIZET 3 UP AIR CONDUIT AND DIFFUSER ASSEMBLY This is a division of application Ser. No. 2,112, filed Jan. 12, 1970, now US. Pat. No. 3,823,652.

BACKGROUND OF THE INVENTION This invention relates to air conduit and diffuser assemblies and more particularly to such assemblies which are mounted below the ceiling in a room in full view.

Conventionally in modern buildings, a false decorative ceiling is spaced (usually hung) from the actual room ceiling. The spaced between the false ceiling and the actual ceiling forms an attic. This attic contains recessed lighting fixtures, heating and air conditioning duct systems, sprinkler systems, and other conduits that provide power, telephone, etc. to the room. However, suspended false ceilings are costly and are for the most part only decorative in function. A false ceiling does little more than provide a decorative appearance and attic space that could not be done by the real ceiling itself.

Therefore in some buildings, the provision of a false ceiling has been eliminated, and the actual ceiling of the room, usually the underside of the floor above, is the only ceiling provided. With the elimination of the false ceiling, the attic space has been eliminated also. However, the room still needs the services heretofore supplied by the ducts and other conduits mounted in the attic space between the real ceiling and the false ceiling.

Therefore, it is a primary object of this invention to provide a novel tubular air conduit and air diffuser assembly which will mount below the ceiling of a room in full view but with hidden air diffuser outlets.

It is an object of this invention to provide such an air conduit and diffuser assembly which will carry conditioned air to and distribute the same into a room while providing space for additional service components without a false ceiling and an attic space.

It is another object of this invention to provide such an air conduit and diffuser assembly, which also mounts a light fixture to provide indirect lighting for the room.

It is yet another object of this invention to provide such an air conduit and diffuser assembly for an overhead T concrete deck which mounts below the deck and has mounted thereon a light fixture which is hidden from view from any occupant of the room below the overhead T concrete deck.

It is a further object of this invention to provide such an air conduit and diffuser assembly which has means provided therewith for absorbing sound.

It is yet a further object of this invention to provide such an air diffuser assembly for an overhead T concrete deck with generally upwardly facing diffuser openings but which direct the air generally diagonally downwardly along the assembly sides to prevent the air from hitting the lower end of the T and thereby being directed straight downwardly in a vertical stream.

It is another object of this invention to provide such an air conduit and diffuser assembly which has the diffuser openings located in the upper portion or support panel.

It is yet another object of this invention to provide such an air conduit and diffuser assembly having an upper portion or support panel with diffuser openings which receives different sizes of lower skins to form a central cavity of different sizes.

It is further objectyof this invention to provide such an air conduit and diffuser assembly having a universal support panel for a variety of sizes of assemblies.

SUMMARY OF THE INVENTION An air conduit and diffuser assembly for use below the ceiling of a room to conduct air form a supply into the room and to diffuse it throughout the room including conduit or air plenum means having a central cavity to conduct air therealong and a plurality of generally outwardly directed diffuser openings therethrough to diffuse the air throughout the room, and attaching means attaching the conduit means in the room under the ceiling in visual and air flow communication with room areas below the ceiling. The air diffuser assembly can also include mounting means associated therewith for mounting a visually hidden light fixture thereon. The air diffuser assembly may be comprised of individual support panel sections and individual duct panel sections together by attaching means to be assembled into the air conduit and diffuser assembly.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is partially cut away view of a pre-cast double- T concrete deck which acts as a ceiling for the room below and which has mounted thereto an air conduit and diffuser assembly according to the preferred embodiment of this invention for diffusing air throughout the room below and for mounting a light fixture or the like thereon;

FIG. 2 is an enlarged cross-sectional view taken along the plane IIII of FIG. 1 showing the central crosssection of the air conduit and diffuser assembly of FIG.

FIG. 3 is an enlarged section view of the portion of FIG. 2 enclosed in rectangle III and showing the details of construction of the air conduit and diffuser assembly of FIG. 1;

FIG. 4 is a partially exploded view of the air conduit and diffuser assembly of FIG. 1 showing the method of construction.

FIG. 5 is a partially cut away and partially exploded view of a floor which acts as a ceiling for the room below and which has mounted thereto an alternative exemplary embodiment of the air conduit and diffuser assembly, according to this invention, for diffusing air throughout the room below;

FIG. 6 is an enlarged cross-sectional view taken along the plane 66 of FIG. 5 showing the central crosssection of the alternative exemplary embodiment of the air conduit and diffuser assembly of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT having a light bulb 17 mounted in between mounting ends 18.

While the ceiling 13 is shown in the exemplary embodiment as being the underside of a pre-cast double concrete deck 10, it should be understood that the ceiling 13 for mounting the air diffuser assembly 15 may be any type of a ceiling.

The air diffuser assembly 15 generally includes conduit means of an upper portion or support panel 21 and a lower portion or duct 50 surrounded by a decorative skin 60 and attached to the ceiling by attaching means 30. The conduit 20 has mounting means 70 for mounting the light fixture 16 thereon and securing means 71 for maintaining the light fixture mounted thereon. The air diffuser assembly 15 may be provided with canal means 80 including utility support means 90 inside the conduit means 20 for conducting various utilities and other services into the room.

As best seen in FIGS. 1 and 2, the upper portion or support panel 21 of the conduit means 20 is made up of a multiplicity of elongated support panel sections or U-shaped members 22 having an inverted hat-shaped cross-section. Each support panel section 22 has an upwardly opening light fixture receiving cavity 23 bounded by a web 24. The web 24 has outwardly and downwardly extending side flanges 25 with each flange 25 having a radially inwardly directed lip or jag 26 therein. The jags 26 have a series of metering openings 27 in the upper leg thereof which lie in radial planes through the conduit assembly for allowing a limited amount of air to pass through the support panel sections 22. Each support panel section 22 has notches at either side of both ends to facilitate securing the support panel sections together. The support panel sections 22 are each mounted to the ceiling 13 by attaching means or hanging means 30.

As best seen in FIG. 2, the attaching means 30 includes a pair of parallel centrally-located spaced keyways 31 in the ceiling 13. The keyways 31 have an inverted trapezoidal cross-section for receiving and maintaing therein, feet 32. The feet 32 have threaded holes for receiving the threaded upper ends 33 of rods 34. The rods have a threaded lower ends 35 which extend through centrally located openings 36 in the support panel section 22 and receive nuts 37 to attach each support panel section 22 in spaced relationship from the ceiling 13. A plurality of nuts 37 are provided to act as leveling means 38 to permit the aligning and leveling of the support panel sections 22.

Splice means 40 is provided for attaching adjacent end to the support panel sections 22 together to form the support panel 21. As best seen in FIG. 4, the splice means includes a plurality of alignment bands 41, with each band 41 extending from the one side of the flange 25 of a support panel section 22 below the support panel section and around to the other side of the support panel section in an open loop for receiving the duct 50. A pair of spaced holes 42 are provided in the alignment band 41 adjacent either end thereof which may be aligned with holes 43, at either side of both ends of support panel sections 22 with sheet metal screws 44 being screwed therethrough to secure the alignment band 41 to the support panel sections 22 while securing the support panel sections 22 together to form a support panel 21.

The lower portion or duct 50 is made of a multiplicity of duct sections or insulating material 51 from a high density insulation glass formed in a generally tubular shape. The length of the duct sections 51 corresponds to the length of the support panel sections 22. The duct sections 51 may be provided with heat reflective foil 52 either along the interior side or sandwiched between the sides in a special slot provided therefor, depending upon the particular use intended for the air diffuser assembly 15.

The duct sections 51 after being rolled into a generally tubular shape, are inserted inside the loop of the alignment bands 41 to secure the duct sections 51 to the support panel sections 22 and form the duct sections 51 in alignment into a duct 50. The support panel 21 and the duct together form a central cavity 55 for carrying air or other services into the room 14.

A decorative skin is provided around the duct 50 and the support panel 21 to enhance the appearance of the air diffuser assembly 15. The decorative skin 60 is made of a multiplicity of skin sections 61 having a sound absorbing surface of uniform perforations 62. The skin sections 61 are of a corresponding length to the length of the support panel sections 7'. and wrap around the duct sections 51 with each end thereof around the alignment bands 41 to be attached to the flanges 25 of the support panel sections 22 and the alignment bands 41 by sheet metal screws 63. The skin sections 61 meet each other at adjacent ends to form a butt joint forming a continuous decorative skin 60 which, besides enhancing the appearance of the air diffuser assembly 15, also absorbs sound in the room 14.

The skin sections 61 of the decorative skin 60 cover the lips or jags 26 of the support panel sections 22. A diffuser opening 64 is provided over each of the metered openings 27 for diffusing the air from the central cavity 55, through the metered openings 27 and through the decorative skin 60, generally tangentially, to the conduit outer surface into the room 14. Seal means 65 in the form of sponge rubber gaskets 66 as best seen in FIG. 4 are provided between the jags 26 and the decorative skin 60 below the diffuser openings 64 in the chamber 67 formed thereby, to prevent the air passing through the metering openings 27, from passing between the decorative skin 60 and the duct 50. Thus the air in the central cavity 55 will follow the path shown by the arrows in FIG. 3.

Mounting means 70 is provided in the conduit means 20 for mounting a light fixture or the like thereto. The particular mounting means of the preferred embodiment includes the cavity 23 in each support panel section 22 which are aligned as the sections 22 are attached into the support panel 21. The light fixture 16 is inserted into the cavity 23 and maintained therein by securing means 71 which in the preferred embodiment are turn clamps mounted on the rods 33 and pivoted over the light fixture 16 in the cavity 23. Notice in FIG. 2 that the light fixture 16 when positioned in the cavity 23 has the light bulb 17 thereover extending between mounting ends 18, but that the light bulb 17 is hidden from view by the conduit means 20 throughout the room because of the downwardly extending portions 11 of the ceiling l3 restricting the line of sight. Thus the light fixture 16 mounted on the conduit means 20 provides hidden lighting to a room 14 having no false ceilmg.

The air diffuser assembly 15 may have one end thereof attached to a supply of conditioned or heated air (not shown) for conducting the conditioned or heated air into the room 14 permitting the air to be diffused through the metered openings 27 and the diffuser openings 64 throughout the room 14. The metering openings 27 are so sized to permit only a limited amount of air to pass therethrough so that all of the openings 27 will have generally the same amount of air passing therethrough for any given flow in the central cavity 55. The diffuser openings 64 are larger and generally located in the upper half of the conduct means 20 to diffuse the air passing through the metering openings 27. Additionally the location of the diffuser openings 64 in the upper half of the conduct means 20 tends to hide the openings 64 from view giving a clean decorative appearance from below in the room 14 uninterrupted by the utilitarian diffuser openings.

The conditioned or heated air from the supply (not shown) enters the central cavity 55 with a high velocity pressure and with a higher static pressure to pass down the central cavity 55. At each metered opeing 27 a limited amount of air passes therethrough into the upper end of chamber 67 between the jags 26 of the support panel 21 and the skin 60 where the velocity of the air is reduced and the static pressure increased before passing out the diffuser openings 64. The diffuser openings 64 are much larger than the metering opening 27 so the velocity of the air therethrough is much less, giving less noise. Notice in FIG. 3 that the diffuser openings 64 are adjacent the lower end of the chamber 67 between the panel 21 and the skin 60 causing the air to flow along the skin 60 for a short distance until the momentum of the air cause it to break free of the skin 60. The flow of diffused air along the skin prevents the air from flowing against the downwardly extending portions 11 of the T deck to be deflected thereby in a stream down at the floor and the occupants of the room.

If the diffuser assembly is not to be used with a T- deck. then chamber 67 and separated metering and diffuser openings may not be necessary and the common openings in the skin will both meter and diffuse the air.

The air diffuser assembly may act as a return or exhaust by drawing air from the room through the diffuser openings 64 and the metering openings 27 into the central cavity 55 to be conducted thereby. Also, the air diffuser assembly may also be used to conduct other services than air conditioning or heating into the room 14.

Canal means 80 may be located within the central cavity 55 of the air diffuser assembly 15 to divide central cavity 55 into the utility carrying portion 56 and an air carrying portion 57. The canal means 80 is shown in the preferred embodiment as an elongated U-shaped open upperended channel 81 having inwardly extending flanges 82 with openings 83 therethrough for receiving the thread lower ends of rods 33 to be attached within the central cavity 55 by nuts 84. The channels 81 may be made in a multiplicity of channel sections of lengths similar to the support panel sections and may be attached to the rods 33 prior to the duct sections 51 being inserted into the alignment bands 41.

The channels 81 may be provided with utility support means such as ring clamps or conduit 91 to segregate the particular utilities such as telephone, electrical, sprinkler systems, etc. within the channel 81 while the utilities are conducted throughout the room by the air diffuser assembly 15. Suitable conduits (not shown) can be provided for passing the utilities out of the air conduit and diffuser assembly 15 at the desired locations.

Referring now to FIGS. 5 and 6, and particularly to FIG. 5, an alternative exemplary embodiment of the air conduit and diffuser assembly 15 according to this invention is generally indicated by the number 115. This alternative embodiment of the air conduit and diffuser assembly 115 is mounted below and from the ceiling 113 in thr room 114. The ceiling 113 is defined by the horizontal surface portion 112 of a pre-cast concrete deck 110. Notice that the pre-cast concrete deck is flat across the lower surface and has no downwardly extending portions.

While the ceiling 113 is shown in the exemplary embodiment as being the underside of a pre-cast concrete deck 110, it should again be understood that the ceiling 113 for mounting the air conduit and diffuser assembly 115 may be any type of ceiling.

The air conduit and diffuser assembly 115 according to the alternative embodiment includes conduit means of an upper portion or support panel 121 and a lower portion or skin 160 to be attached to the ceiling by attaching means 130.

As best seen in FIG. 5, the upper portion or support panel 121 of the conduit means 120 is made up of a multiplicity of elongated support panel sections 122 having a hat-shaped cross-section. Each support panel section 122 has downwardly opening hat-shaped portion 123 bounded on either side by a web 124. The web 124 has downwardly and outwardly extending flexible side flanges 125. A plurality of diffuser openings 127 are located in both vertical sides of the downwardlyopening hat-shaped portion 123 to open the interior of the support panel 122 to the room 114. Each support panel section 122 has a notch 128 at either side of both ends to facilitate the securing of the support panel sections together. The support panel sections 122 are each mounted to the ceiling 13 by attaching means 130.

As best seen in FIG. 6, the attaching means 130 includes a keyway 131 in the ceiling 113. A keyway 131 has an inverted trapezoidal cross-section for receiving and maintaining therein a plurality of feet 132. The feet 132 have threaded holes for receiving the threaded upper ends 133 of rods 134. The rods 134 have a threaded lower end 135 which extend through centrally located openings 136 in the support panel sections 122 and receive nuts 137 to attach the support panel sections in spaced relationship from the ceiling. A plurality of nuts 137 are provided to act as leveling means 138 to permit the aligning and leveling of the support panel sections 122.

Splice means 140 is provided for attaching adjacent ends of the support panel sections 122 together to form a support panel 121. As best seen in FIGS. 4, the splice means 140 include a plurality of alignment bands 141.

. Each band 140 extends from one side flange 125 of a support panel section 122 below the ends of adjacent support panel section 122 and around to the other side of the support panel section 122 in a loop. A pair of spaced holes 142 are provided in the alignment bands 141 adjacent either end thereof. The holes 142 may be aligned with the holes 143 at either side of both ends of the support panel sections 122 with sheet metal screws 144 being screwed therethrough to secure the alignment band 141 to the support panel sections 122 and to secure the support panel sections 122 together to form a support panel 121.

A lower portion or skin 160 is provided around the alignment bands 141 to form a central cavity 155 for carrying air into the room 114. The skin 160 is made up of a multiplicity of skin sections 161 of corresponding lengths to the length of the support panel sections 122. The skin sections 161 are wrapped around the alignment bands 141 and attached to the flanges 125 of the support panel sections 122 by sheet metal screws 163. The skin sections 161 meet each other at adjacent ends to form a butt joint to form a continuous appearing skin 160. Any gap that might occur at the butt joint of the skin sections 161 is closed by the alignment bands 141 on the inside thereof.

With the diffuser openings 127 being in the support panels 121, the skin 60 need not be specially made to include any openings as in the preferred embodiment. With a universal skin 160 being useable, a central cavity 155 can be of any size as long as the skin 161 and the alignment bands 141 being of a corresponding size. The support panel sections 122 of the alternative embodiment of the air conduit and diffuser assembly 115 can be made for universal use to make all sizes of air I diffuser assembly.

If after installation and/or during addition to a room, more capacity is desired. the alternative embodiment of the air diffuser assembly 115 need not be completely replaced but may merely have the skin 160 and the alignment bands 141 replaced to provide the added capacity desired. The alternative exemplary embodiment /of the air conduit and diffuser assembly 115 provides simplified and universal construction.

Thus the air conduit and diffuser assembly according to this invention mounts below the real ceiling of a room in full view to conduct conditioned air into the room to be diffused throughout the room.

I claim:

1. A method of assembling and mounting an air conduit and diffuser assembly below a ceiling of a room comprising the steps of:

securing attaching means to the ceiling;

mounting support panel sections to the attaching means with the ends of the sections adjacent each other;

securing an alignment band between the adjacent ends of adjacent support panel sections to form a support panel;

inserting tubular duct sections between the alignment bands and under the support panels to form a tubular duct having a central cavity for carrying air from a supply to be diffused throughout the rooms.

2. A method as recited in claim 1 wherein the step of leveling the support panel sections occurs after the step of securing the alignment band and before the step of inserting the tubular duct.

3. The method as in claim 1 additionally including the steps of:

wrapping a sound absorbing decorative skin around the duct and the alignment bands, and

attaching the skin to the panel.

4. The method as in claim 1 wherein the step of mounting a utilities channel below the support panel occurs after the step of securing the alignment band, said support panel being within the cavity of the duct.

5. A method of assembling and mounting an air conduit and diffuser assembly below a ceiling of a room, comprising the steps of:

securing attaching means to the ceiling;

mounting support panel sections to the attaching means with the ends of the sections adjacent each other;

securing an alignment band between the adjacent ends of adjacent support panel sections to form a support panel;

wrapping a skin around the alignment bands; and

attaching the skin to the panel. 

1. A method of assembling and mounting an air conduit and diffuser assembly below a ceiling of a room comprising the steps of: securing attaching means to the ceiling; mounting support panel sections to the attaching means with the ends of the sections adjacent each other; securing an alignment band between the adjacent ends of adjacent support panel sections to form a support panel; inserting tubular duct sections between the alignment bands and under the support panels to form a tubular duct having a central cavity for carrying air from a supply to be diffused throughout the rooms.
 2. A method as recited in claim 1 wherein the step of leveling the supPort panel sections occurs after the step of securing the alignment band and before the step of inserting the tubular duct.
 3. The method as in claim 1 additionally including the steps of: wrapping a sound absorbing decorative skin around the duct and the alignment bands, and attaching the skin to the panel.
 4. The method as in claim 1 wherein the step of mounting a utilities channel below the support panel occurs after the step of securing the alignment band, said support panel being within the cavity of the duct.
 5. A method of assembling and mounting an air conduit and diffuser assembly below a ceiling of a room, comprising the steps of: securing attaching means to the ceiling; mounting support panel sections to the attaching means with the ends of the sections adjacent each other; securing an alignment band between the adjacent ends of adjacent support panel sections to form a support panel; wrapping a skin around the alignment bands; and attaching the skin to the panel. 